Three-dimensional analysis for optimizing thermo-hydrodynamic performance of heat exchangers with perforated semi-circular inserts

This study focuses on the current energy crisis, highlighting the challenges and opportunities it presents, particularly in the electricity, coal, and natural gas sectors. In this context, a compact and efficient heat exchanger has been developed to recover waste heat from power plants and industries, thus promoting energy savings. The aim of this study is to enhance the thermal performance of this heat exchanger by combining two methods. By analyzing various parameters such as the Nusselt number and thermal performance factor across a range of Reynolds numbers and using different fluids, the study reveals the positive impact of semi-circular inserts on thermal performance. Results show a significant improvement in thermal performance factor with the addition of inserts, particularly in case (4) where it reaches 1.86 at a Reynolds number of 140,000. Additionally, the study compares five perforated models, demonstrating that model (2) stands out as the most thermally efficient, with a maximum value of 1.8787 at a Reynolds number of 140,000. Perforations in the inserts promote better fluid flow uniformity and reduce pressure losses. In conclusion, the optimal configuration, specifically model (2) with perforations, exhibits superior thermal and hydrodynamic performance, providing valuable insights for thermal engineering and heat exchanger optimization in various industrial and technological applications. The findings of this study offer tangible prospects for thermal engineering, providing important guidelines for heat exchanger design and optimization, with significant implications for a wide range of industrial and technological applications, and offering a solid foundation for future research in the field of heat transfer and fluid thermodynamics.